Flame retardant polyurethane products

ABSTRACT

By providing a polyol-based component and an isocyanate-based component, along with one or more flame retardant and/or smoke suppressant additives, in a reactive, injection molding process, rigid, polyurethane, foam products are achieved which are capable of exceeding all applicable standards for flame retardancy, while also comprising a density ranging between about 2 lbs. per cubic foot and 50 lbs. per cubic foot. In achieving a desired rigid polyurethane products of the present invention, the flame retardant and/or smoke suppressant additives may comprise one or more selected from the group consisting of organic additives, inorganic additives, halogenated additives, and non-halogenated additives. Furthermore, in the preferred embodiment, the three-dimensional rigid, polyurethane, foam products of the present invention comprises a thickness ranging between about 0.1 inches and 6 inches, a width ranging between about 0.1 inches and 96 inches, and an overall length ranging between about 0.1 inches and 288 inches.

TECHNICAL FIELD

This invention relates to polyurethane foam compositions employed fordecorative moldings, structural members, and the like, and, moreparticularly, to such products formed from polyurethane foamcompositions which are capable of complying with Class A flameretardancy standards.

BACKGROUND ART

The commercial decoration industry is a relatively mature industrywherein numerous products have been created to satisfy consumer demandsand requirements. In particular, architectural or decorative moldingshave been widely employed for centuries, in order to provide visualappealing accents or decorative effects to homes and structures. Inaddition, decorative moldings are also used to cover rough edges orimperfections that may have been created during the construction of thehome or building.

Typically, architectural or decorative moldings are employed bothindoors and outdoors as molding accents, structural members in doorcasings, railings, and replacement materials for wood in the furnitureindustry. Originally, architectural or decorative moldings weremanufactured from wood. However, more recently, polystyrene, polyvinylchloride, and gypsum have been employed for such products. Althoughpolystyrene and polyvinyl chloride are inexpensive materials which canbe produced easily and economically into suitable decorative products,these prior art products have been generally incapable of complying withClass A requirements for flame retardancy.

The only true material which is in compliance with these specificationsis gypsum. However, since wood has been accepted in the industry forcenturies, wood continues to be usable for such products, even thoughthe flame retardancy standards are not met by wooden products.

In addition, wood and gypsum suffer from significant disadvantages.Since wood is a natural product, it is costly to produce due to thelabor involved in harvesting, preparing and producing the product in awide variety of different shapes. Furthermore, wood is also limited totwo-dimensional products, without the aid of slow and expensivemanufacturing processes.

Gypsum products are more flexible for three-dimensional shaping.However, the manufacturing processes are very laborious and expensive.Typically, forms must be poured in small sections by skilled artisansand are extremely heavy and awkward to manipulate and install. As aresult, both wood and gypsum have inherent challenges that createhardships whenever these materials are used to create products for thecommercial/residential decoration industry.

In order for any material, other than wood, to be acceptable forapplications in the indoor/outdoor building industry as decorativemoldings, structural members in door casings, railings, and replacementmaterials for wood in the furniture industry, the material must meet orexceed the specifications consistent with Class A flame retardancystandards as defined in ASTM E-84. In this standard, two parameters aretested, namely flame spread and smoke density.

Flame spread is the propagation of combustible flaming along the lengthof the material. Limiting flame spread in a material is critical tolimiting the volume of the fire and heat release rates which can lead toflashover of the fire into other areas of the structure. In accordancewith this standard, the flame spread rating, which is expressed as theresult of a ratio, must not exceed 25.

Smoke is the number one cause of injury and death in fires. As a result,the second aspect associated with ASTM E-84 is smoke density. Largeamounts of smoke replace the oxygen in the area of the fire with carbondioxide, carbon monoxide, and other toxic gases. This causes suffocationor poisons the victims. It is critical to control the amount and type ofgases generated in a fire to help save lives and property. In accordancewith the accepted standard, smoke density, which is expressed as theresult of a ratio, must not exceed 450.

In general, prior art attempts to meet these standards using materialsother than wood or gypsum have been unsatisfactory. Typically,conventional polyurethane has severe weaknesses associated withflammability. The material is extremely combustible which promotes flamespread, high rate of heat release, and dense black smoke. The densityranges of these products also make it extremely difficult to reducesmoke generation.

Prior art polyurethane products have been created which are capable ofmeeting Class A flame retardancy standards. However, these productscomprise low density formulations, typically less than 2 pounds percubic foot, and have not been accepted in the commercial decorationmarket due to their low quality and their inability to provide anappearance which emulates a high end product and provides the look,feel, and handling characteristics associated with wood.

Therefore, it is a principal object of the present invention to providea rigid, polyurethane, foam product which is capable of satisfyingvirtually every flame retardancy standard, in general, and the Class Aflame retardancy standards defined in ASTM E-84, in particular.

Another object of the present invention is to provide a rigid,polyurethane, foam product having the characteristic features describedabove, which comprises a density ranging between about 2 lbs. per cubicfoot and 50 lbs. per cubic foot.

Another object of the present invention is to provide a rigid,polyurethane, foam product having the characteristic features describedabove which is capable of being manufactured using a reactive, injectionmolding process.

Another object of the present invention is to provide a rigid,polyurethane, foam product having the characteristic features describedabove which is capable of being manufactured in 3-dimensional profileshaving any desired size and/or shape. Another object of the presentinvention is to provide a rigid, polyurethane, foam product having thecharacteristic features described above which achieves a flame spreadrating that does not exceed 25 and a smoke density rating which does notexceed 450.

Other and more specific objects will in part be obvious and will in partappear hereinafter.

DETAILED DISCLOSURE

By employing the present invention, all of the difficulties anddrawbacks found in the prior art products have been overcome and rigidpolyurethane foam products have been achieved which are capable of beingemployed for a wide variety of products in the indoor/outdoor buildingindustry, while also being fully compliant with Class A flame retardancystandards as defined in ASTM E-84. By employing the present invention,products such as decorative moldings, structural members in doorcasings, railings, and replacement materials for wood in the furnitureindustry are obtained.

Furthermore, the performance of the materials of the present inventionis also suitable for use in installation applications, such as hot waterpipes, wall and roof systems, and appliance installations due to theproduct's compliant performance in flammability under CaliforniaTechnical Bulletin 117, UL 94 HB, UL 94 HBF, UL 94 V2, and UL 94 VO. Inaddition, products manufactured in accordance with the present inventionare also acceptable for entertainment applications, such astwo-dimensional and three-dimensional sculptures, motion picturedecorations, commercial play area decorations, and other applicationsassociated with UL 1975 (100 kW).

It is also been found that products manufactured in accordance with thepresent invention pass the performance standards defined by FederalMotor Vehicle Safety Standard 302. As a result, products manufactured inaccordance with the present invention can be used in the automotiveindustry for such products as head-liners, seat components, door anddashboard decorations, under-hood applications, and any other automotiveapplication requiring compliance with this Standard.

Furthermore, it has been found that material manufactured in accordancewith the present invention is acceptable for use in the commercialairline industry as molding or decorations on commercial airplanes, seatarmrests, and other in-plane applications, due to the ability of thepresent invention to be in compliance with performance requirementsdefined in FAR 25.853a.

In accordance with the present invention, the desired components orproducts are formed from rigid polyurethane foam composites having adensity ranging between about 2 pounds per cubic foot and 50 pounds percubic foot. In addition, these products are all capable of meeting orexceeding the Class A flame retardancy standards as defined by ASTME-84.

Furthermore, products manufactured in accordance with the presentinvention also meet Class A Specifications, a standard most otherpolyurethane products manufactured in the United States are incapable ofmeeting. These accomplishments are achieved in the present invention byincorporating aggressive flame retardants and unique combinations ofsmoke suppressants into the reactive injection molded polyurethaneprocess.

By employing the present invention, products are produced which areflame retardant and exceed Class A specifications. In addition, productsmanufactured in accordance with the present invention are also capableof being manufactured as three-dimensional products, light-weight andeasily installable decorations, while also providing substantially lowercost, economical production capabilities.

In accordance with the present invention, reactive, injection molded,rigid polyurethane products are produced which exceed the requiredspecifications for Class A flame retardant material as defined by ASTME-84 (25 flame spread, 450 smoke density). In the preferred embodiment,the rigid polyurethane products comprise a density ranging between about2 pounds per cubic foot and 50 pounds per cubic foot. It has also beenfound that the polyurethane products of the present invention maycomprise densities ranging between about 7 pounds per cubic foot and 24pounds per cubic foot, with densities ranging between about 9 pounds percubic foot and 20 pounds per cubic foot being optimal. In addition, therigid polyurethane products manufactured in accordance with the presentinvention are enhanced by incorporating organic and/or inorganic flameretardants and smoke suppressants.

In the present invention, the reactive system comprises two principalingredients, namely an isocyanate based component and a polyol-basedcomponent. Preferably, the isocyanate based component comprises at leastone selected from the group consisting of methyl-di-isocyanates,di-isocyanurates, poly-methyl-di-isocyanates, poly-di-isocyanurates, andisocyanates. In addition, the polyol-based component comprises at leastone selected from the group consisting of polyesters, polyethers, andpolyols. As detailed below, these materials are generally intermixed atvarious proportions to create specifically desired foam properties.

In order to enhance the reactive, injection molded, rigid polyurethanematerials with the desired, unique, flame retardant properties, one ormore organic and/or inorganic flame retardants and/or smoke retardantsuppressants are incorporated into the composition, along with one ormore smoke suppressants. Preferably, the flame retardants and smokesuppressants comprise one or more selected from the group consisting ofmagnesium hydroxide, talc, quartz, silica, tin oxide, aluminumtri-hydrate, molybdenum oxate, zinc stanate, and boron hydride. Althoughone or more of these compounds have been found to be highly effective inenhancing the resulting product by substantially reducing flame spreadand smoke density, the use of aluminum tri-hydrate and zinc stanate arepreferred.

It has also been discovered that in employing the organic and/orinorganic flame retardants and/or smoke suppressants compounds detailedabove, the desired flame retardants and/or smoke suppressants may bemetered into the composition of the present invention as an additionalstream during the intermixing of the isocyanate based components and thepolyol based components. In addition, if desired, the flame retardantsand/or smoke suppressants may be premixed into one or both of the mainreactive materials.

Regardless of the process employed for intermixing the desired flameretardants and/or smoke suppressants, the compositions employedpreferably comprise a sufficient quantity of the desired compounds torange between about 0% by weight and 95% by weight, based upon theweight of the entire composition. Although the foregoing percentageshave been found to be efficacious, it has also been found that the flameretardants and/or smoke suppressant compositions preferably rangebetween about 0% by weight and 75% by weight, based upon the weight ofthe entire composition, with a range of between about 0% by weight and65% by weight, based upon the weight of the entire composition, beingoptimum.

In addition, it has also been found that halogenated or non-halogenatedcompounds selected from the group consisting of decabromadiphenyl oxide,octabromadiphenyl oxide, hexabromadiphenyle oxide, small-chainednon-cyclic brominated compounds, chlorinated parrafins, cyclic andnon-cyclic chlorinated compounds, boron containing materials, phosphatecontaining materials, and any other organic materials which may be usedto retard flame spread or smoke generation may be employed to retardflame spread or smoke generation. Preferably, these compounds areemployed in quantities ranging between about 0% by weight and 95% byweight, based upon the weight of the entire composition. Furthermore,these compounds may be employed in the composition as flame retardantsand/or smoke suppressants either by direct metering into the compositionor pre-mixing these ingredients into one or both of the main reactivestreams.

Although the foregoing ranges have been found to be efficacious, it hasbeen found that the halogenated and non-halogenated compounds detailedabove are preferably employed in quantities ranging between about 0% byweight and 50% by weight, based upon the weight of the entirecomposition. In addition, quantities ranging between about 0% by weightand 25% by weight, based upon the weight of the desired composition,have been found to be optimum.

In producing reactive, injection molded, rigid polyurethane products inaccordance with the present invention, it has been found that theisocyanate based component preferably comprises between about 25 partsand 75 parts of the overall composition. In addition, the polyol-basedcomponent preferably comprises between about 50 and 150 parts of theoverall composition.

In addition, in formulating the preferred polyurethane products inaccordance with the present invention, the isocyanate based componentspreferably comprise between about 5% by weight and 95% by weight, basedupon the weight of the entire composition. In addition, it has beenfound that quantities of these components preferably range between about25% by weight and 75% by weight, based upon the weight of the entirecomposition, with a range of between about 45% by weight and 65% byweight, based upon the weight of the entire composition, being optimum.

Furthermore, the preferred polyurethane products of the presentinvention comprise between about 5% by weight and 95% by weight, basedupon the weight of the entire composition, of the polyol basedcomponent. In addition, quantities of the polyol based componentpreferably range between about 25% by weight and 75% by weight, basedupon the weight of the entire composition, with quantities rangingbetween about 45% by weight and 65% by weight, based upon the weight ofthe entire composition, being optimum.

In the most preferred formulations, aluminum tri-hydrate and zincstanate are employed for the flame retardants and smoke suppressants. Inthis regard, the composition incorporates these components in quantitiesranging between about 0% and 50% by weight, based upon the weight of theentire component, and more preferably between about 0% and 25% byweight, based upon the weight of the entire composition.

In preparing the preferred formulation of the present invention, blowingagents are preferably employed in the formation process. Although anyblowing agents capable of generating a foam product in the desireddensity ranges can be employed, provided the blowing agent meets firespecifications of Class A products, it has been found that the blowingagent preferably comprises one or more selected from the groupconsisting of water, carbon dioxide, pentane, isopentane, butane,isobutene, hexane, heptane, HCFC 141b, HCFC 134a, and HCFC 245fa.

In addition, it has been found that the quantity of blowing agentincorporated into the composition ranges between about 0% and 95% byweight, based upon the weight of the entire composition, with betweenabout 0% and 35% by weight, based upon the weight of the entirecomposition, being preferred and between about 0% by weight and 25% byweight, based upon the weight of the entire composition, being optimum.Furthermore, the blowing agent can be metered as a separate stream intothe reactive ingredients or, if desired, mixed into one or both of themain reactive streams.

In forming the desired reactive, injection molded, rigid polyurethaneproducts in accordance with the present invention, it has been foundthat the product preferably comprises a thickness ranging between about0.1 inches and 6 inches. In addition, a thickness ranging between about0.1 inches to 3 inches is more preferred, with a thickness rangingbetween about 0.1 inches and 1.25 inches been optimum.

Furthermore, the rigid polyurethane products also preferably comprise awidth ranging between about 0.1 inches and 96 inches. In addition, awidth ranging between about 0.1 inches and 48 inches is more preferred,while a width ranging between about 0.1 inches and 30 inches is optimum.Finally, the overall length of product produced in accordance with thepresent invention preferably range between about 0.1 inches and 288inches. In addition, a length ranging between about 0.1 inches and 192inches is preferred, while a length ranging between about 0.1 inches and144 inches is optimal.

It has also been found that the processing parameters employed inmanufacturing the polyurethane foam materials of the present inventioncan be optimized to accommodate different densities. This processoptimization was accomplished by empirically modifying the raw materialstorage temperatures, modifying the line feeding temperatures, modifyingthe injection head temperatures, and modifying the mold temperatures tochange the viscosity and reaction times of the components. Theparameters that were studied included mold filling tendency, mixingconsistency, cream time, rise time, “free rise” density and tact time.

Mold filling tendency is defined as the ability of the materials tocomplete the detail present within the mold during the pouring andcuring process. The viscosity of the blended material during injectionand rise are critical to produce a detailed continuous part.

Mixing consistency pertains to the ability of the components to becombined in a consistent, single-phase system. This is a complex issuedue to the addition of solids into the system and the difference in theviscosities between the isocyanate and the polyol streams. In order toachieve the desired results, the powders are metered into the polyolliquid by weight either manually or be the use of mechanical feedingsystems. By conditioning the polyol liquid to elevated temperatures, thesolubility of the powders into the liquid is greatly improved. It hasalso been found that the blade design and speed also play major factorsin the production of a consistent premix polyol component.

Once the powders are thoroughly mixed, the components are loaded intothe storage/metering tank where the temperature is monitored andoptimized. This composition must be continually agitated to preventsettling.

The isocyanate is loaded into another storage/metering tank where thetemperature is monitored and optimized. The temperatures should becontrolled to achieve as similar as possible viscosities between the twocomponents. During trials, it has been found that storage temperaturefor both components range between about 50° F. to 140° F. However, thematerials started to show signs of degradation about 100° F. Thematerials' viscosities proved to be most similar around 90° F. whichproved to be the target storage temperature for both components.

In addition, humidity is kept to an absolute minimum because of thereactivity of the isocyanate with atmospheric moisture. This can beachieved with the addition of an inert gas blanket inside the storagecontainer.

Also, mixing consistency is greatly influenced by the dynamic mixingthat occurs when the materials are mixed. Low pressure machines providethe best opportunity to optimize this process since they are routinelyoutfitted with dynamic mixing elements. The raw material streams are feddirectly into a mixing chamber where specialty designed mixing elementsrigorously whip the materials into a consistent soup. In high pressuremachines, it is imperative to match the viscosities of the inletstreams, the velocities of the inlet streams, and orifice sizes of theinlet streams to achieve a consistent blend because the mixing isdependent on the dynamic interchange of the materials themselves in themixing chamber.

The “cream time” is the next critical parameter to be optimized in thesystem. Because we have several processes in which this material can berun, it is necessary to match the reaction times of the materials to ourmanufacturing process. The “cream time” is defined as the time at whichthe materials start to react to begin cross-linking once they areintroduced to each other. In our processes, these times must vary fromas little as 1 second to as much as 240 seconds. However, the “creamtime” preferably ranges between about 1 second and 120 seconds, with a“cream time” ranging between about 1 second and 60 seconds beingoptimal. These changes can once again be influenced by temperature. Thehigher the temperature, the shorter the “cream time”. Conversely, thelower the temperature, the longer the “cream time”. The “cream time” mayalso be considerably influenced by the catalyst concentrations.

Catalysts are introduced to lower the activation energies to help beginreactions. The levels of these catalysts are controlled by the rawmaterial supplier depending on the need to begin the reactions. It israther easy to control the rate of these reactions with the adjustmentof these catalysts levels.

It is important to maintain the longest “cream time” that iseconomically feasible to ensure the material has time to flow into thecrevices of the mold. The viscosity before cream is the lowest thatexists in the mixed system.

The next parameter that is important is the “rise time” of the material.The “rise time” is defined as time from when the material creams untilit ceases to grow in volume. The “rise time” is dependent on the degreeof cross-linking in the system and the amount of blowing agent that ispresent. The degree of cross-linking is important because it determinesviscosity of the fluid during rise (expansion). Therefore, it also lendsgreat value to filling detailed moldings. The degree of cross-linkingalso provides melt strength to the material to allow for expansionwithout rupturing or cracking. Typically, the “rise time” ranges betweenabout 5 seconds and 900 seconds. However, a “rise time” ranging betweenabout 15 seconds and 600 seconds is preferred, while a “rise time”ranging between about 30 seconds and 420 seconds is optimum.

If the “rise time” is not long enough, the material will rise fasterthan cross-linking is occurring, thereby causing cracks and ruptures inthe foam. The amount of blowing agent present is also important tocontrol the “rise time”. The reactive injection molding process is anexothermic process which generates its own heat to volatilize theblowing agent. The blowing agent continues to volatilize until it iscompletely consumed. The volatilized material produces pressure withinthe crosslinked web which allows the polyurethane to expand and producefoam.

The amount of blowing agent determines the “free rise” density of thematerial. The “free rise” density is defined as the density achievedwith full volatilization of the blowing agent within the polyurethanefoam without any restrictions on the volumetric expansion. Whendeveloping a mold, a good rule of thumb is to have the “free rise”density of the material to be roughly half of the completed partdensity. This will allow for pressurized expansion within the mold andcomplete filling of the part.

The final parameter that is critical for the consideration of apolyurethane part is “tact time”. “Tact time” is defined as the point atwhich the polyurethane material is capable of being touched by anoutside agent without adhering or stringing away from the rest of thematerial body. The actual chemical phenomenon is described as the pointat which the rise is complete and the cross-linking reactions arefinished. The material is rigid and the surface texture is hard.

Typically, the tact time ranges between about 5 seconds and 90 seconds.However, a tact time ranging between about 15 seconds and 600 seconds ispreferred, with a tact time ranging between about 30 seconds and 420seconds being optimum.

The processes described above can be implemented in three methods formanufacture: open-pour reactive injection molding process, continuousreactive injection molding process, and closed-mold reactive injectionmolding process. Each of these processes is capable of utilizing moldtooling constructed for solid metals, porous metals, wood, moldedthermosets, thermoplastics, silicones, or any other material suitablefor the processing temperatures, pressures, and release propertiesrequired to achieve a good part.

In addition, each of the processes may be implemented with the use ofall conventional mold release techniques, such as “permanently” coatedmolds, commercial mold releases, organic waxes, pressurized air,impregnated removal tools, in-mold films (releasable or investmentcast), or any other method of mold release to allow a clean departurefrom the molding material. Each of the processes may also be processedwith all conventional metering equipment, including high pressure andlow pressure machinery, available today for processing two-part reactiveinjection molding materials.

Other possibilities include reducing/removing the amount powder from thepolyol component and including part or all of it into the isocyanatestream or feeding it in as an additional stream. The mixing may besufficient in the dynamic mixing head to accommodate the dispersionwithout a premixing step in the process. The blowing agents may also beintroduced by an additional stream to control the amount of foaming.

Once products were produced employing the present invention, it becameevident that the materials have all of the requisite properties whichare necessary for use in the indoor-outdoor building industry asdecorative moldings, structural members in door casings, railing, andreplacement materials for wood in the furniture industry. Furthermore,the performance of these materials made the products suitable for use ininsulation applications such as hot water pipes, wall and roof systems,and appliance insulations, due to its compliant performance inflammability to UL 94 HB, UL 94 HBF, UL 94 V2, and UL 94 VO. Also, thematerial performed acceptable for entertainment applications such as twodimensional and three dimensional sculptures, motion picturedecorations, commercial play area decorations, and all otherapplications associated with UL 1975 (100 kW). Finally, the material isacceptable for use in the airline industry as molding decoration oncommercial airlines, seat armrests, and other in-plane applications dueto its passing performance in FAR 25.853a.

The finished polyurethane foamed products of the present inventiontypically comprise an average cell size ranging between about 0.001 and10 mm. In this regard, however, an average cell size ranging betweenabout 0.001 mm and 3 mm is preferred, with an average cell size rangingbetween about 0.001 mm and 1 mm being optimal.

Furthermore, the foamed polyurethane product may be coated with a flameretardant coating which can consist of a single component or a mixtureof such materials as halogenated flame retardant compounds,non-halogenated flame retardant compounds, intumescent flame retardantcompounds, inorganic materials, or any other type of material suitableto maintain the Class A specifications fire rating for the applicationthickness of the entire composite. In addition, the flame retardantcoating may be applied to the foamed composition in a thickness from 0mils to 120 mils to achieve the Class A specifications fire rating forthe application thickness of the entire composition.

BEST MODE FOR CARRYING OUT THE INVENTION

In order to demonstrate the efficacy of the present invention, numerousfoamed polyurethane products were constructed from various formulationsof the present invention and manufactured using the processes detailedabove. Each of the resulting foamed polyurethane products were testedfor comparative purposes in order to establish the ability of eachformulation to meet the flame retardant standards defined by Class A ofASTM E-84. The results of this testing program are provided below.

Table I provides the results achieved for the flame spread and smokedensity, in accordance with the standards defined by Class Aspecification of ASTM E-84, for each of the different examples ofproducts manufactured and tested in the first test program. In eachproduct tested, polyol and isocyanate were employed as the mainreactants, with each of these compound streams incorporating 60% byweight, based upon the weight of each stream, of aluminum tri-hydrate.In addition, the polyol reactants in Examples 1 and 2 also incorporateda bromated organic flame retardant, while the remaining Examplesemployed an off-the-shelf flame retardant. TABLE I Density Example(LBS/FT³⁾ FLAME SPREAD SMOKE DENSITY 1 24 40 884 2 18 43 896 3 15 32 3384 24 29 461 5 24 30 591

In order to improve the test performance results and attain a productcapable of fully satisfying the flame retardancy requirements of a ClassA product as defined by ASTM E-84, the formulation of the foamedpolyurethane product defined by Example 3 was employed as a control witha wide variety of coatings being applied thereto. In this regard,flame-retardant, organic/inorganic reactive intumescent coatings wereemployed, along with flame-retardant, epoxy-based, coatings andflame-retardant latex coatings.

The test data achieved from this program is detailed in Table II. As isevident from these results, the reactive intumescent coatings proved tobe the most effective as a fire blocked and smoke suppressor. Inaddition, the coatings were evaluated using the after-flame time of UL94 HB as a qualifier. TABLE II Average After- After- Flame FlameDescription of Time Time Coating Coating Event (Sec) (sec) Blank NoCoating 1 31 Blank No Coating 2 34 Blank No Coating 3 18 27.6 ControlWhite Solvent-Based 1 35 Barrier Coat Control White Solvent-Based 2 50Barrier Coat Control White Solvent-Based 3 55 46.7 Barrier Coat 10—10Flame Control Intumescent Paint 1 15 10—10 Flame Control IntumescentPaint 2 5 10—10 Flame Control Intumescent Paint 3 3 7.7 FX 100 CoatingNo Barrier Paint 1 25 FX 100 Coating No Barrier Paint 2 4 FX 100 CoatingNo Barrier Paint 3 10 13 FX 100 Coating White Solvent-Based 1 10 BarrierCoat FX 100 Coating White Solvent-Based 2 13 Barrier Coat FX 100 CoatingWhite Solvent-Based 3 5 9.3 Barrier Coat 40—40 Flame Control IntumescentPaint 1 23 40—40 Flame Control Intumescent Paint 2 23 40—40 FlameControl Intumescent Paint 3 40 34.3

In the final group of tests which were conducted in order to clearly andunequivocally demonstrate the ability of the present invention to complycompletely with the standards defined and ASTM E-84, foam polyurethaneproducts were constructed with a one inch thickness, using theformulation and processes detailed above. This product was constructedwith a density of 12 pounds per cubic foot and was coated with 10⁻¹⁰flame control intumescent paint.

Three separate and independent samples were prepared and tested, asrequired by ASTM E-84, wherein the Standard requires three consecutivetest results to be performed with the average of all three testsresulting in a flame spread of 25 or less and a smoke density of 450 orless. As detailed and Table III, the results of these three tests areshown. TABLE III FLAME SPREAD SMOKE DENSITY  12.8 (15) 65.383 (65) 15.79(15) 58.065 (60) 16.93 (15)  151.5 (150)* 15.17 (15) Average  91.6(150)** Average*Since the sample is an outlier, the test method requires reporting theaverage as the high value.**The test method requires that all of the values be rounded to thenearest 5 for averaging.

It will thus be seen that the object set forth above, among those madeapparent from the preceding description, are efficiently obtained andsince certain changes may be made in carrying out the above process andas a composition set forth without departing from the scope of theinvention, it is intended that all matter contained in the abovedescription shall be interpreted as illustrative and not in a limitingsense.

It is also to be understood that the following claims are intended tocover all of the generic and specific features of the invention hereindescribed, and all statements of the scope of the invention which, as amatter of language, might be said to fall therebetween.

Particularly it is to be understood that in said claims, ingredients orcompounds recited in the singular are intended to include compatiblemixtures of such ingredients wherever this sense permits.

1. A rigid, polyurethane, foam product constructed for satisfying ClassA flame retardancy standards and comprising: A. a density rangingbetween about 2 lbs. per cubic foot and 50 lbs. per cubic foot; B.between about 5% and 95% by weight based upon the weight of the entirecomposition of a polyol-based component; and C. between about 5% and 95%by weight based upon the weight of the entire composition of anisocyanate-based component; whereby a rigid polyurethane foam product isobtained which is capable of being employed in a wide variety ofconfigurations and used in a wide variety of alternate applications andindustries.
 2. The rigid, polyurethane, foam product defined claim 1,wherein said density ranges between about 7 lbs. per cubic foot and 24lbs. per cubic foot.
 3. The rigid, polyurethane, foam product definedclaim 1, wherein said density ranges between about 9 lbs. per cubic footand 20 lbs. per cubic foot.
 4. The rigid, polyurethane, foam productdefined in claim 1, and further comprising at least one flame retardantand/or smoke suppressant additive incorporated therein.
 5. The rigid,polyurethane, foam product defined in claim 4, wherein said flameretardant and/or smoke suppressant is further defined as comprising oneselected from the group consisting of organic and inorganic additives.6. The rigid, polyurethane foam product defined in claim 5, wherein saidorganic and/or inorganic additives are further defined as comprising atleast one selected from the group consisting of aluminum trihydrate,magnesium hydroxide, talc, antimony trioxide, quartz silica, molybdenumoxate, tin oxide, zinc stanate, or any other materials that prohibitsthe generation of flame spread or smoke density, and act as flameretardants, smoke suppressants, reactive synergists, and/or catalysts.7. The rigid, polyurethane foam product defined in claim 6, wherein saidinorganic and/or organic additive is further defined as being containedin at least one selected from the group consisting of the polyol-basedcomponent and the isocyanate-based component
 8. The rigid, polyurethane,foam product defined in claim 6, and further comprising at least oneblowing agent selected from the group consisting of water, CO², pentane,isopentane, butane, isobutene, hexane, heptane, HCFC 141b, HCFC 134a,HCFC 245fa, or any other blowing agent capable of generating a foamedproduct in the appropriate density range.
 9. The rigid, polyurethanefoam product defined in claim 8, wherein the blowing agent is furtherdefined as being contained in at least one selected from the groupconsisting of the polyol-based component and the isocyanate-basedcomponent.
 10. The rigid, polyurethane, foam product defined in claim 4,wherein said isocyanate-based component is further defined as comprisingat least one selected from the group consisting ofmethyl-di-isocyanates, di-isocyanurates, polymethyl-di-isocyanates,poly-di-isocyanurates, and isocyanates.
 11. The rigid, polyurethane,foam product defined in claim 10, wherein said polyol-based component isfurther defined as comprising at least one selected from the groupconsisting of polyesters, polyethers, and polyols.
 12. The rigid,polyurethane, foam product defined in claim 11, wherein said flameretardant and/or smoke suppressant additive is further defined ascomprising at least one selected from the group consisting of magnesiumhydroxide, talc, quarter, silica, tin oxide, aluminum tri-hydrate,molybdenum oxate, zinc stanate, and boron hydride.
 13. The rigid,polyurethane, foam product defined in claim 12, wherein said flameretardant and/or smoke suppressant additive is further defined ascomprising at least one selected from the group consisting of aluminumtrihydrate and zinc stanate.
 14. The rigid, polyurethane, foam productdefined in claim 11, wherein said flame retardant and/or smokesuppressant additive is further defined as comprising at least oneselected from the group consisting of halogenated compounds andnon-halogenated compounds.
 15. The rigid, polyurethane, foam productdefined in claim 10, wherein said halogenated and/or non-halogenatedflame retardant and/or smoke suppressant additive is further defined ascomprising at least one selected from the group consisting ofdecabromadiphenyl oxide, octabromadiphenyl oxide, hexabromadiphenyleoxide, small-chained non-cyclic brominated compounds, chlorinatedparrafins, cyclic and non-cyclic chlorinated compounds, boron containingmaterials, phosphate containing materials, and any other organicmaterials which may be used to retard flame spread or smoke generation.16. The rigid, polyurethane, foam product defined in claim 15, whereinsaid halogenated and/or non-halogenated flame retardant and/or smokesuppressant additive is further defined as being contained in at leastone selected from the group consisting of the polyol-based component andthe isocyanate-based component.
 17. The rigid, polyurethane, foamproduct defined in claim 1, and further comprising between about 25% and75% by weight based upon the weight of the entire composition of theisocyanate-based component and between about 25% and 75% by weight basedupon the weight of the entire composition of the polyol-based component.18. The rigid, polyurethane, foam product defined in claim 1, andfurther comprising between about 45% and 65% by weight based upon theweight of the entire composition of the isocyanate-based component andbetween about 45% and 65% by weight based upon the weight of the entirecomposition of the polyol-based component.
 19. The rigid, polyurethane,foam product defined in claim 1, wherein said product comprises athickness ranging between about 0.1 and 6 inches, a width rangingbetween about 0.1 and 96 inches, and a length ranging between about 0.1and 288 inches.
 20. The rigid, polyurethane foam product defined inclaim 19, wherein said product is further defined as comprising athickness ranging between about 0.1 and 3 inches, a width rangingbetween about 0.1 and 48 inches, and a length ranging between about 0.1and 192 inches.
 21. The rigid, polyurethane foam product defined inclaim 19, wherein said product comprises a cell size ranging betweenabout 0.001 mm. and 10 mm.
 22. The rigid, polyurethane foam productdefined in claim 22, wherein said product is coated with a flameretardant coating comprising one selected from the group consisting ofhalogenated flame retardant compounds, non-halogenated flame retardantcompounds, intumescent flame retardant compounds, and inorganicmaterials.
 23. The rigid, polyurethane foam product defined in claim 22,wherein said coating is further defined as having a thickness rangingbetween about 0 and 0.120 inches.
 24. The rigid, polyurethane foamproduct defined in claim 1, wherein said product is constructed to befully compliant with at least one flame retardancy standard selectedfrom the group consisting of ASTM E-84, UL 94 VO, UL 1975, FMV SS 302,California Technical Bulletin 117, and FAR 25,853.a.
 25. A rigid,polyurethane, foam product constructed for satisfying Class A flameretardancy standards and comprising: A. a density ranging between about2 lbs. per cubic foot and 50 lbs. per cubic foot; B. between about 5%and 95% by weight based upon the weight of the entire composition of apolyol-based component comprising at least one selected from the groupconsisting of polyesters, polyethers and polyols; C. between about 5%and 95% by weight based upon the weight of the entire composition of anisocyanate-based component comprising at least one selected from thegroup consisting of methyl-di-isocyanates, di-isocyanurates,poly-methyl-di-isocyanates, poly-di-isocyanurates, and isocyanates; D.at least one flame retardant and/or smoke suppressant additiveincorporated therein and comprising at least one selected from the groupconsisting of magnesium hydroxide, talc, quarter, silica, tin oxide,aluminum tri-hydrate, molybdenum oxate, zinc stanate, and boron hydride;E. a thickness ranging between about 0.1 and 6 inches, a width rangingbetween about 0.1 and 96 inches, and a length ranging between about 0.1and 288 inches; and F. a cell size ranging between about 0.001 mm and 10mm. whereby a rigid polyurethane foam product is obtained which iscapable of being employed in a wide variety of configurations and usedin a wide variety of alternate applications and industries.
 26. Areactive, injection molding method for producing a rigid polyurethane,foam product constructed for satisfying Class A flame retardancystandards and comprising a density ranging between about 2 lbs. percubic foot and 50 lbs. per cubic foot, between about 5% and 95% byweight based upon the weight of the entire composition of a polyol-basedcomponent and between about 5% and 95% by weight based upon the weightof the entire composition of an isocyanate-based component, and saidmethod of production comprises one selected from the group consisting ofopen-pour reactive injection molding, continuous reactive injectionmolding, and closed-mold reactive injection molding.
 27. A method forproducing a rigid, polyurethane, foam product comprising the steps of:A. thoroughly mixing a polyol-based component in a first mixing vessel;B. thoroughly mixing an isocyanate-based component in a second mixingvessel; C. loading the contents of the first mixing into a firststorage/metering tank and continuously agitating the contents thereof;D. loading the contents of the second mixing vessel into a secondstorage/metering tank and continuously agitating the contents thereof;E. controlling the temperature of the contents in the first and secondmetering tanks to range between about 50° F. and 140° F.; F. deliveringa stream of the polyol-based component into a mixing chamber; G.delivering a stream of the isocyanate-based component into the mixingchamber; H. balancing the polyol-based component to comprise a ratioranging between about 50 and 150 parts of the overall composition andthe isocyanate-based component to comprise a ratio of between about 25parts and 75 parts of the overall composition; I. rigorously mixing thecontents of the mixing chamber into a substantially uniform composition;and J. delivering the intermixed composition to a desired reactive,injection molding equipment for forming the desired, rigid, polyurethaneproduct.
 28. The method defined in claim 27, comprising the additionalstep of: K. Adding at least one flame retardant and/or smoke suppressantadditive to the formulation.
 29. The method defined in claim 28, whereinthe flame retardant and/or smoke suppressant additive comprises one ormore selected from the group consisting of organic additives, inorganicadditives, halogenated additives, and non-halogenated additives.
 30. Themethod defined in claim 29, wherein said additive is further defined asbeing added to the formulation by employing at least one processselected from the group consisting of metering each additive into themixing chamber as a separate stream, adding each additive to thepolyol-based mixing vessel, and adding the additive to theisocyanate-based mixing vessel.